NANOFIBER ENHANCED FUNCTIONAL FILM MANUFACTURING METHOD USING MELT FILM CASTING

• US 20110212321A1
• Filed: 04/27/2009
• Published: 09/01/2011
• Est. Priority Date: 04/25/2008
• Status: Abandoned Application

• Current Assignee: University of Akron
• Original Assignee: University of Akron
• Inventors: Yalcin, Baris, Cakmak, Miko, Sarkar, Soumayajit
• Application Number:
  US12/989,509
• Publication Number:
  US 20110212321A1
• Time in Patent Office: Days
• US Class Current: 428/323
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2264/00 Composition or properties of particles which form a particulate layer or are present as additives
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2264/12 Mixture of at least two particles made of different materials
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/7163 Biodegradable
• CPC Class Codes: B32B 2457/18 Fuel cells
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/28 comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D01D 5/0084 : Coating by electro-spinning, i.e. the electro-spun fibres are not removed from the collecting device but remain integral with it, e.g. coating of prostheses
• CPC Class Codes: D04H 1/728 : by electro-spinning electro-spinning methods and apparatus D01D5/0007
• CPC Class Codes: D04H 13/00 : Other non-woven fabrics
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles

Abstract

The present invention generally relates to a method for producing hybrid materials of thin polymer films with single, laminated, complete and/or partially embedded nanofibers to obtain products with unique functional properties. In one embodiment, the present relates to a hybrid process that utilizes both melt casting and electrospinning to produce nanofiber embedded functional films. In another embodiment, the process of the present invention involves nanofiber-containing products that are formed by producing a plurality of nanofibers via one or more nanofiber producing nozzles; depositing such nanofibers onto a melt cast polymer film; and either partially and/or completely embedding such nanofibers into the melt cast polymer film via one or more electrical forces.

Claims

1. A method for producing a nanofiber-polymer film combination, the method comprising the steps of:

(A) producing a polymer film via a melt casting process, wherein the melt cast polymer film is receptive to one or more layers of nanofibers;

(B) depositing one or more layers of nanofibers on the melt cast polymer film.

2. The method of claim 1, wherein the one or more layers of nanofibers have an average diameter in the range of 3 nanometers to about 3,000 nanometers.

3. The method of claim 1, wherein the one or more layers of nanofibers have an average diameter in the range of about 7 nanometers to about 1,000 nanometers.

4. The method of claim 1, wherein the one or more layers of nanofibers have an average diameter in the range of about 10 nanometers to about 500 nanometers.

5. The method of claim 1, wherein the polymer film is formed nylon, nylon n family of polymers, nylon n/m family of polymers, aliphatic and aromatic polyesters, biodegradable polymers, a thermoplastic polymer composition that exhibits medium to low viscosity, low molecular weight polymers, or suitable combinations of two or more thereof.

6. The method of claim 5, wherein the polymer film is formed from a polycaprolactone (PCL).

7. The method of claim 1, wherein the nanofibers are formed from any polymer compound that can be electrospun.

8. The method of claim 7, wherein the nanofibers are formed from polyethylene oxide.

9. The method of claim 1, wherein the nanofibers are formed from any polymer compound that can be subjected to a nanofiber by gas jet process.

10. The method of claim 1, wherein at least two nanofibers layers are sequentially deposited on the polymer film, wherein each nanofiber layer is individually formed by one or more distinct electrospinning apparatuses.

11. The method of claim 1, wherein the nanofiber-polymer film combination further comprises one or more nanoparticles selected from metal nanoparticles, inorganic nanoparticles, organic nanoparticles, nano-material precursors, nanomaterials, nanofibers, or a combination of two or more thereof.

12. A product formed via the method of claim 1.

13. A method for producing a nanofiber-polymer film combination, the method comprising the steps of:

(a) producing a polymer film via a melt casting process, wherein the melt cast polymer film is receptive to one or more layers of nanofibers;

(b) subjecting the melt cast polymer film to at least one heating zone;

(c) depositing one or more layers of nanofibers on the melt cast polymer film.

14. The method of claim 13, wherein the one or more layers of nanofibers have an average diameter in the range of 3 nanometers to about 3,000 nanometers.

15. The method of claim 13, wherein the one or more layers of nanofibers have an average diameter in the range of about 7 nanometers to about 1,000 nanometers.

16. The method of claim 13, wherein the one or more layers of nanofibers have an average diameter in the range of about 10 nanometers to about 500 nanometers.

17. The method of claim 13, wherein the polymer film is formed nylon, nylon n family of polymers, nylon n/m family of polymers, aliphatic and aromatic polyesters, biodegradable polymers, a thermoplastic polymer composition that exhibits medium to low viscosity, low molecular weight polymers, or suitable combinations of two or more thereof.

18. The method of claim 17, wherein the polymer film is formed from a polycaprolactone (PCL).

19. The method of claim 13, wherein the nanofibers are formed from any polymer compound that can be electrospun.

20. The method of claim 19 wherein the nanofibers are formed from polyethylene oxide.

21. The method of claim 13, wherein the nanofibers are formed from any polymer compound that can be subjected to a nanofiber by gas jet process.

22. The method of claim 13, wherein at least two nanofibers layers are sequentially deposited on the melt cast polymer film, wherein each nanofiber layer is individually formed by one or more distinct electrospinning apparatuses.

23. The method of claim 13, wherein the nanofiber-polymer film combination further comprises one or more nanoparticles selected from metal nanoparticles, inorganic nanoparticles, organic nanoparticles, nano-material precursors, nanomaterials, nanofibers, or a combination of two or more thereof.

24. A product formed via the method of claim 13.